Volkswagen New Beetle. Manual - part 813

 

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Volkswagen New Beetle. Manual - part 813

 

 

MASTER CYLINDER PUSH ROD 

PARKING BRAKE 

1. Press brake pedal firmly 3 times. Operate parking brake lever 3 times. Disengage parking brake. Raise 

and support vehicle. Measure gap between stop and lever. See Fig. 7 . Maximum clearance between 
parking brake lever (on caliper) and stop should be .059" (1.5 mm). If clearance is not as specified, go to 
next step.  

2. Remove center console extension. See CENTER CONSOLE under REMOVAL & INSTALLATION.  

3. Loosen locking nuts at parking brake lever. Tighten adjusting nuts until levers on calipers just move off 

stops. Apply and release parking brake. Ensure rear wheels rotate freely. Recheck adjustment, and adjust 
as necessary. Tighten lock nuts.  

NOTE:

Master cylinder push rod is not adjustable. 

NOTE:

Due to self-adjusting rear brakes, adjustment is normally only necessary after 
replacing parking brake cables, brake calipers, brake pads and/or brake discs, 
backing plate or brake linings. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:17 AM

Page 12 

© 2004 Mitchell Repair Information Company, LLC. 

Fig. 7: Adjusting Parking Brake 
Courtesy of VOLKSWAGEN UNITED STATES, INC. 

WHEEL BEARINGS 

Front and rear wheel bearings, also called hub or axle bearings, are sealed units. Bearings are not adjustable. For 
repair information on wheel bearings, see appropriate FRONT or REAR article in SUSPENSIONS.  

TROUBLESHOOTING 

BRAKE PAD WEAR INDICATOR 

Brake pads that have reached the end of their service life are indicated on instrument cluster by the Brake Pad 
Wear Indicator. Indicator will go out when NEW brake pads with NEW brake pad wear sensors are installed on 
vehicle.  

SYSTEM TESTING 

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:17 AM

Page 13 

© 2004 Mitchell Repair Information Company, LLC. 

BRAKE BOOSTER BRAKE ASSIST 

Vehicles manufactured from 02/2002 are equipped with brake assist. To test brake assist, start engine and 
depress brake pedal to ensure full vacuum boost. When brake pedal is depressed, a "click" must be audible, 
activating mechanical brake assist. Brake pedal can now be partially released and pressed again with less force. 
It is not possible to repair the brake assist, complete brake booster must be replaced.  

ELECTRIC VACUUM PUMP 

Description & Function (ITT Mark 60 ABS) 

The electric vacuum pump is only installed in vehicles equipped with automatic transmission. Pump is switched 
on by Engine Control Module (ECM) dependent on intake manifold pressure. Vacuum pump is On Board 
Diagnostic (OBD) capable. There are no provisions for servicing the electric vacuum pump. If a malfunction is 
detected the vacuum pump must be replaced. Vacuum pump is located lower left on the subframe. See Fig. 8 .  

Fig. 8: Locating Electric Vacuum Pump (ITT Mark 60 ABS)

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:17 AM

Page 14 

© 2004 Mitchell Repair Information Company, LLC. 

Courtesy of AUDI OF AMERICA, INC. 

Testing (ITT Mark 60 ABS) 

1. Drive vehicle onto lifting platform, turn engine off. Start engine. While the engine is being started the 

electric vacuum pump should run briefly. Electric vacuum pump is located on subframe in front of 
steering box, left side. Have an assistant touch the pump by hand to check whether it is running.  

2. If electric vacuum pump does not run, check fault memory in the engine control module. See appropriate 

SELF-DIAGNOSTICS article in ENGINE PERFORMANCE. If no DTCs were stored in memory, 
perform circuit testing of vacuum pump. See CIRCUIT TESTING .  

3. If problem is found, repair as necessary. If no problem with wiring is found, replace electric vacuum 

pump. See ELECTRIC VACUUM PUMP under REMOVAL & INSTALLATION.  

VACUUM CHECK VALVE 

To check function of check valve, blow air through valve. Air must pass through in direction of arrow. See Fig. 
9
 . Valve must remain closed in opposite direction. Ensure that check valve is installed correctly.  

Fig. 9: Checking Function Of Vacuum Check Valve 
Courtesy of VOLKSWAGEN UNITED STATES, INC.

 

2003 Volkswagen New Beetle GLS 

1998-2004 BRAKES Disc - New Beetle

  

Helpmelearn Repair Manuals 

 

Wednesday, December 14, 2005 7:59:17 AM

Page 15 

© 2004 Mitchell Repair Information Company, LLC. 

 

 

 

 

 

 

 

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